Dunkirk 90-50 Installation, Operation & Maintenance Manual
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Dunkirk 90-50 Installation, Operation & Maintenance Manual

Gas-fired, directvent, condensing, hot water boiler
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See also: Installation Manual
GAS-FIRED, D IRECT VENT,
CONDENSING, HOT WATER BOILER
INSTALLATION, OPERATION &
MAINTENANCE MANUAL
DUNKIRK
BOILERS
85 Middle Rd.
Dunkirk,
NY 14048
www. dunkirk, com
P/N# 14683301, Rev.C [12/2010]

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  • Page 1 GAS-FIRED, D IRECT VENT, CONDENSING, HOT WATER BOILER INSTALLATION, OPERATION & MAINTENANCE MANUAL DUNKIRK BOILERS 85 Middle Rd. Dunkirk, NY 14048 www. dunkirk, com P/N# 14683301, Rev.C [12/2010]...
  • Page 2 90-75 90= 1 O0 These instructions must be affixed on or adjacent to the boiler. Improper installation, adjustment, alteration, service, or maintenance can cause injury or property damage. Refer to this manual. For assistance or additional information consult a qualified installer, service agency, or the gas supplier.
  • Page 3 Warnings and Safety Symbols ....................... Introduction ..........................Boiler Ratings & Capacities ......................Boilers For Use At High Altitude ..................... Rules For Safe Installation And Operation ..................Before Installing The Boiler ......................Pladn( The Boiler ........................Near Boiler Piping ........................Combustion Air and Vent Pipe ......................
  • Page 4 (sealed combustion) and does not compete with building occupants This appliance is a gas-fired direct vent hot water boiler with cast for fresh air. Sealedcombustion (also known as "direct vent") is the aluminum boiler sections. A revolutionary cast aluminum heat safest and best wayto obtain plenty of clean combustion air.
  • Page 5 90-50 2" CPVC & PVC 90-75 2" CPVC & PVC 90-100 2" CPVC & PVC * 1 MBH = 1,000 Btuh Btuh = British Thermal Units Per Hour These low pressure gas-fired hot water boilers are design certified The Net I=B R Ratings shown are based on a piping and pickup by CSA International for use with natural and propane gases.
  • Page 6 The boilers (with the exception of the 90-75LP product) are factory Note that 90-75 LP applications for 5,000- 10,000 feet above sea equipped for operation at altitudes ranging from 0-10,000 feet above level will require an orifice change as well as a gas manifold pres- sea level.
  • Page 7 i_i_i_i_i_i_i_i_i_i_i_i_i_i_i_i_i_i_i_i_i_i_i_i_i_i_i_i_i_i_i_i_i_i_i_i_i_i_i_i_i_i_i_i_i_i_i For model 90-75 LP units only at altitudes above 5,000 ft., install 90-75 High Altitude Orifice Kit #550001810*. For all other altitudes use factory installed orifice. TABLE #2: SERIES90 PROPANE GAS Altitude in Ft. 0-5,000 5,000-10,000 Normal Input (MBH) Manifold Pressure In W.C.
  • Page 8 1. Read t heentire installation manual before b eginning the instal- Follow a regular service and maintenance schedule for efficient lation. Failure t ofollow these r ules forsafe i nstallation and and safe operation. operation and these i nstructions could cause amalfunction oftheboiler a nd result i ndeath, serious bodily injury, a nd/or Keep boiler area clean of debris and flee of combustible and flammable rnaterials.
  • Page 9 Considerations For Boiler Location In the event that the side wall horizontally vented gas fueled equiprnent is installed in a crawl space or an attic, Before selecting a location for the boiler, the following should be the hard wired carbon rnonoxide detector with alarm and considered.
  • Page 10 6. Advise o wner o fboiler t okeep venting a nd combustion air sphere, and all flue products are discharged to outside atmosphere. intake passages free ofobstructions, boththe venting a nd corn- Cornbustion air and vent pipe connections rnust terrninate together bustion a irintake piping systems connected totheoutdoors in the same atmospheric pressure zone, either through the roof rnust permit f lowthrough t hepiping systerns...

  • Page 11: Foundation Requirements

    moval of an existing boiler, the following steps shall be followed with Condensate Drain Requirements each appliance rernaining connected to the common venting systern Condensate drain line to be pitched down to floor drain at a mini- placed in operation, while the other appliances rernaining connected rnurn of 1A"...
  • Page 12 When the installation of the boiler is for a new heating system, first install all of the radiation units (panels, radiators, baseboard, or tub- The circulator pump and isolation valves ing) and the supply and return mains. After all heating system piping furnished within a carton...
  • Page 13 Figure 3 - Multi-zone Boiler Piping With Zone Valves ZONE SERVICE VALVE ZONE SUPPLYTO \JAWE ZONES ZONESERVICE VAWE CIRCU LATOR FROM ZONES PURGE (DRAIN) VALVES VALVE...
  • Page 14 Figure4 - Multi-Zone BoilerPipingWithCirculators ZONE SERVICE VALVE FLOW CHECK SUPPLYTO ZONES VALVE "\ CIRCULATORS FLOW CHECK VALVE RETURNFROM ZONES PURGE (DRAIN) VALVES SERVICE VALVE When zoning with circulators, the furnished circulator pump should be used as one of the zone pumps. Each stripped end of the electrical wires for the circulator...

  • Page 15: Discharge Piping

    Figure5 - SingleZoneBoilerPiping DISCHARGE PIPING Pressure Relief V alve Expansion Tank And Make-Up Water The boiler is furnished with a factory installed reliefvalvein the top Deterrnine required systern fill pressure, systern design ternperature, of the boiler. Provide 3_,, p iping frorn the supplied reliefvalveto a and systern water content.
  • Page 16 Figure 6 - Diaphragm Type Expansion Tank Piping MANUAL FILL VALVE AUTOMATIC AIR VENT _ 3/4"xI/8" BUSHING _ 3/4" TEE_ 3/4" NIPPLE (FURNISHED AND INSTALLED ON PACKAGED BOILER) 3/4" STREET ELL* COLD WATER FILL FURNISHED IN PARTS BAG. DIAPHRAGM TYPE EXPANSION TANK COMBINATION QUICK FILL...

  • Page 17: Cold Water

    Figure 7 - Conventional (closed type) Expansion Tank Piping CLOSEDTYPE EXPANSION TANK EXPANSION TANK SERVICE VALVE (GATE VALVE OR FULL PORT BALL VALVE) MANUAL FILL VALVE COLD WATER FILL CHECK AND PRESSURE REDUCING VALVE...
  • Page 18 Figure8 - Condensate D rainPiping OPEN DRAIN PIPETO BE PITCHED DOWN TO FLOOR DRAIN AT A MINIMUM _"-'-'\'\\'_" "" "\\-- T01/4" PER FOOT DRAIN _"\_v_ CONDENSATE DRAIN THREADED NIPPLE (PVC) (INSTALLED) PVCTEE 1/2 SLIPxl/2 SLIPx 1/2 NPT FURNISHED IN PARTSBAG Condensate Drain Piping Filling Condensate...
  • Page 19 Chilled Water Piping The boiler piping system of a hot water boiler connected to heat- ing coils is located in air handling units where they may be exposed The boiler, when used in connection with a refrigeration system, to refrigerated air circulation must be equipped with flow control must be installed so the chiller medium is piped in parallel with the valves or other automatic means to prevent gravity circulation of the boiler with appropriate valves to prevent the chilled medium...
  • Page 20 Combustion air and vent piping lengths: 2 FEET 21 FEET 15 FEET 92 FEET 112FEET The first 5 ft. of"TOTAL EQUIVALENT LENGTH" of vent piping Termination should be positioned where it will not be run must be 2" CPVC: subjected to potential damage by foreign objects, such as stones, balls, etc..
  • Page 21 Figure 9 - Roof Vent / intake terminations 8" MINIMUM VERTICAL SEPAPJ_.T[ON BETWEEN COMBUSTION AIR INTAKE AND VENT MAiNTAiN 12" MiNiMUM _// CLEARANCE ABOVE HIGHEST ANTICIPATED SNOW LEVEL USA- 12" (300ram) Canada - 18" (450ram) Vent shall not terminate with 6 ft. (1.8m) of a mechanical air-supply inlet to any building.
  • Page 22 Figure 10A - Side Wail Vent / Intake terminations - Less Than 12" Clearance Above Grade Less Than 12" Clearance Figure 10B - Side Wail Vent / Intake Terminations - 12" Or More Clearance Above Grade...
  • Page 23 Figure11-Combustion Air andVentPiping 2° (S&Smm) COMBUSTION A_R VENT/_NTAKE TERMiNATiONS INTAKE P{PiNG .._. 2" 1508ram) CPVC VENT PIPING (FU RNiSHED) _°-,_,,__ 2" (50,8mm} CPVC COUPLING (FURNISHED 2 * (50,Bmm) DIAMETER VENT AND COMBUSTION AiR iNTAKE P_PING - 15' (4,57m)MAXIMUM LENGTH TOTAL 1,52m W_TH 4 °...
  • Page 24 Installation After pipes have been cut and pre-assernbled, apply cement primer to pipe fitting socket and end of pipe to insertion rnark. Attach cornbustion air intake piping to supplied Fernco 2" cou- Quicklyapply approved cernent to end of pipe and fitting pling on mixer.

  • Page 25: Gas Supply

    Checking The Gas Piping The boiler and its gas connection must be leak tested before placing Never use a match or open flame to test for the boiler in operation. Open the manual shutoff valve. Test for leaks leaks. by applying soap suds (or a liquid detergent) to each joint. Bubbles forming indicate leak.
  • Page 26 _._nr_ai f.t_au_d'. Pump Wiring See Figure 13 (followingpage) for service switchjunction box and Turn off electrical power at fuse box before circulator pump fieldwiring connections. A 5 feet wiring harness iiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiii_ iiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiii making any line voltage connections. Follow with flexiblemetal conduit is supplied to connect the circulator iiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiii iiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiii_ local electrical...
  • Page 27 Figure 13 - Field Wiring Connections 120 VOLT CIRCULATOR BK = BLACK W = WHITE G = GREEN Y = YELLOW 24 VOLT THERMOSTATW NEUTRALq BOILER WIRING tN J-BOX BK HOT _-120 VOLTS SERVICESWITCH EIELD WIRING CONNECTIONS SERVICE SWITCH JUNCTION...
  • Page 28 Figure 14 - D - Schematic Wiring Diagram cD _ cD _ _< _S£S £S8S 8SSS _$ss _Ss< < >- " if any of the 0riginal wire as supplied with this appliance must be replaced, it must be replaced with type 150 °...
  • Page 29 Figure 15 - E - Ladder Wiring Diagram 120 VOLT POWER SUPPLY,/_X HOT' _BLK. ON/OFF SWITCH__f P7-2 P7-1 P7-3 P4-3 P4-1 ", <( ------m ..P10-I CIRCULATOR MOTOR P5-3 P5-1 ' " ' "> DRAFT INDUCER P10-2 HOT SURFACE IGNITER P6-1 P12-1 P12-2...
  • Page 30 This section provides a brief description of the key controls and accessoriesfound in this boiler. The maximum setpoint of the Aquastat must Seethe Troubleshooting section (page47 of the of this installation not exceed 200 °F. manual) for detailed sequences of operation and troubleshooting procedures.

  • Page 31: Circulator Pump

    Draft Inducer Blocked Vent Safety Shutoff The draft inducer (blower) provides a means for pulling combustion This boiler is equipped with a blocked vent safety shutoff rneans, air into and through the mixer, the burner, the flue ways of the which shuts offrnain burner gas in the event that the flow of cast aluminum boiler sections and the flue adapter before being combustion products through the flueways is reduced.

  • Page 32: Piping Recommendations

    When fillingthe boiler w ater isthepreferred heating s olution. Most Cleaning the Hydronic System potable water s upplies may beused tocharge and re-fill p rovided the IMPORTANT: Do not mix different manufacturers' chlorine a nd chloride i ons levels a re less t han100 ppm. products, Doing so will void the warranty of the boiler,...
  • Page 33 iiiii iiiii iiiiii iiiii iiiii iiiiii iiiii iiiii iiiiii iiiii iiiii iiiiii iiiii iiiii iiiiii iiiii iiiii iiiiii iiiii iiiii iiiiii iiiii iiiii iiiiii iiiii iiiii iiiiii iiiii iiiii iiiiii iiiii iiiii iiiiii iiiii iiiii iiiiii iiiii iiiii iiiiii iiiii iiiii iiiiii iiiii...
  • Page 34 Filling Boiler With Water And Purging Air For Systems Placing Boiler In Operation With Diaphragm Type Expansion Tanks Referto the appropriate diagrams in Section VII, "Near Boiler Pip- ing_'for more information. If you do not follow these instructions 1. Close all zone servicevalveson the supply and return piping. exactly, a fire or explosion may result...
  • Page 35 iiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiii 7. Wait five(5) minutes to clear out any gas. Then smell for gas, STOP! Read the safety information above on this label. including near the floor. If you smell gas, STOP! Follow"B" Set thermostat to lowest setting. in the safety information above on this label. If you don't smell Turn off all electric power to the appliance.

  • Page 36: Control Panel

    Verify Proper Sequence Of Operation The sequence can be followed via the diagnostic indicator lamps on the Honeywell $9301A integrated boiler control in Figure #16. This is the normal sequence of operation. A more detailed sequence of operation containing potential faults can be found in the service hints section.
  • Page 37 After pre purge, Lamp B goes out and Lamp C illuminates, in- dicating the hot surface igniter is powered for the 20 second igniter warm-up period. The bright yellow orange glow of the hot surface igniter can be observed through the observation port in the front boiler section just above the igniter.
  • Page 38 Set up U-tube manometer or differential pressure gauge for Test High Limit Control And Adjust measuring manifold pressure, see Figure #17. While burner is operating, move indicator on high limit control Manometer or gauge rnust be able to read at least 0.0 to 3.0 below actual boiler water temperature.
  • Page 39 OUT PROCEDUREAND The following steps and diagram indicate the location of the Refer to "CHECK ADJUSTMENTS" connection points required to measure the manifold pressure. this manual when reading the manifold pressure. When measurement is completed,disconnect the U-Tube The manifold pressure may be measured using a U-Tube Manometer Manometer or Differential Pressure Gauge.

  • Page 40: Installation And Check-Out Certificate

    INSTALLATION AND CHECK-OUT CERTIFICATE Boiler Model Serial # Date Installed Measured BTU/HR input © Installation instructions have been followed © Checkout procedure and adjustments performed © Maintenance and Service issues reviewed with owner/maintenance person © Installation booklet affixed on or adjacent to boiler Installer (Company)
  • Page 41 Check that boiler area is free from combustible materials, Maintenance as outlined below can be performed by the owner unless otherwise noted. gasoline, and other flammable vapors and liquids. The acidic nature of flue gassescondensing on the aluminum boiler Circulator pump and blower motor furnished with boiler are sections will cause the formation of aluminum oxide.
  • Page 42 The following service procedures must be Monthly During Heating Season performed only by a qualified service agency. 1. Remove jacket front and top panels and check for piping Boiler owner should not attempt these leaks around relief valve and other fittings. If found, contact procedures.
  • Page 43 Inspectionofthe flueconnectorrequiresthefollowingsteps(Referto K. Reinstall burner and mixer gasket and position mixer the repairpartsdiagram.) assembly over studs. Install five (5) nuts but do not tighten. A. Loosenthe clamp on the draft inducer end of the 2" Reinstall igniter and igniter gasket and fasten with two flexiblecoupling that connects the vent tee to the draft (2) screws.
  • Page 44 Service Hints THERMOSTAT CALLS HEAT CIRCULATOR ENERGIZES THRU CONTACTS iNTERNAL CiRCUiTRY °2 SEC CONTROL W_LL ATTEMPT ADDITTI:ONAL IGNITION SEQUENCES_ STARTING WITH PREPURGE CLOiSED DOES MA_N BURNER PROVE NORMAL FUME W_TNiN [NmAL OPERATION "TRIAL FOR IGNmON PERIOD? DRAFT INDUCER ENERGIZES THRU 1K1 CONTACTS DURING THE _ST...
  • Page 45 DRAFT INDUCER TEMPERATURE SAFETY SWITCH CASTING TEMPERATURE SAFETY SWITCH IF DRAFT INDUCER TEMPERATURE REACHES IF BURNER OPERATES WHEN BOILER HAS NO TEMPERATURE SAFETY SWITCH SETPOINT, WATER, ALUMINUM BOILER SECTIONS HEAT UP SAFETY SWITCH CONTACTS OPEN IMMEDIATELY RAPIDLY. CLOSING GAS VALVE (LIGHT GOES OUT) CASTING TEMERATURE SAFETY SWITCH CON- TACS WILL OPEN BREAKING 24 VOLT POWER...
  • Page 46 THERMOSTAT ENDS CALL FOR HEAT GAS VALVE AND CIRCULATOR PUMP ARE DE=ENERGIZED AND FLAME LIGHTS GO OUT BLOWER RUNS FOR 30 SECONDS POST PURGE PURGE LIGHT iS "ON" BLOWER iS DE-ENERGIZED FOR30 SECONDS PURGE LIGHT SHUTS "OFF" BOILER STANDS BY FOR NEXT CALL FOR HEAT iii iii iiii iiiiii i i iii i i iii iiiiii ii iii iiiii iiiiii...
  • Page 47 Troubleshooting tools: A. Voltmeter to check 120 vac and 24 vac Fire, explosion or shock hazard may cause Continuity tester. property damage, severe injury or death. Inclined manometer or pressure gauge with 0-2.0" Range Do not attempt to modify the physical (0.01"...

  • Page 49: Troubleshooting Chart I

    TROUBLESHOOTING CHART I GREEN POWER INDICATOR LIGHT ILLUMINATED IBC, ICHART Electrical shock hazard may cause Serious inj ury o r deat h. The following procedures may expose you to _l YES da ng ero us line volta ge. Use ca ut io n to avoid touching live electrical contacts.

  • Page 50: Troubleshooting Chart

    TROUBLESHOOTING CHART 2 CHECK THAT CIRCUIT BREAKER IS ON OR FUSES ARE OK AT THE ELECTRICAL PANEL CHART 1 CHECK THAT SERVICE SWITCH IS ON CHECK CASTING TEMPERATURE SAFETY CHECK WATER LEVEL IN BOILER. CHECK OPEN SWITCH. PUSH RESET BUTTON ON SWITCH. FOR AIR TRAPPED IN TOP OF BOILER.
  • Page 51 TROUBLESHOOTING CHART 3 CHART 1 OPEN CHECK I NO FORVAC REPLACE BETWEEN TERMINALS 1 AND BLOWER STARTS IBC I AT CONNECTOR CN4 ON REPAIR/REPLCE CHECK FOR 120 VAC AT I NO WIRING FROM IBC BLOWER LEADS ON WIRING TO BLOWER HARNESS REPAIR/REPLACE BLOWER...
  • Page 52 TROUBLESHOOTING CHART 4 CHART 3 CHECK FOR 120 VAC IGNITER/SENSOR WARMS BETWEEN TERMINALS UP AND GLOWS AND 2 AT CONNECTOR YELLOW/ORANGE REPLACE IBC DURING 20 SECOND CN1 ON IBC (DURING WARM UP IGNITER WARM UP) CHECK FOR 120 VAC AT IGNITER/SENSOR LEADS REPAIR/REPLACE...

  • Page 53: Troubleshooting Charts

    TROUBLESHOOTING CHART S CHART 4 CHART 4 POSSIBLY MIXTURE TOO LEAN! CHECK GAS LINES DOWNSTREAM OF GAS CLEAN/REPLACE GAS LINES. VALVE FOR BLOCKAGE. BE SURE TO USE CORRECT GASNENTURI VALVE SIZE. GAS LINES CLEAR? IS GAS/VENTURI VALVE CORRECT SIZE? SEE REPAIR PARTS DIAGRAM.
  • Page 54 TROUBLESHOOTING CHART 6 CHART CHART CHART REPLACE GASCONTROL NO #3 rYES CHECK GAS ORFICICE SIZE. IS GAS ORIFICE SIZE CORRECT. CHECK REPAIR PARTS LIST NO #2 FOR CORRECT SIZE, IS GAS ORIFICE CLEAR OF BLOCKAGE, RUNS FOR 25-50 SECONDS, THEN TURNS OFF.
  • Page 55 What Is System Status? The following steps and diagram indicate the locations of the con- nection points required to check the differential air pressure. The differential air pressure switchis a safety devicewhich will Not Running Normally Open prevent the boiler from firing if there is an air intake, boiler heat 1.00"...
  • Page 56 85 Middle Rd. Dunkirk, NY 14048...

This manual is also suitable for:

90-7590-100Quantum 90

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